manroland Develops High-Precision Commercial Printing Press Controller

On a recent project, manroland engineers sought to improve the accuracy of the cut registers on one of the company’s commercial printers. Cut registers position the printed material beneath roller blades before it is cut into individual pages. For high-quality print magazines, cuts must be accurate to within 0.3 mm. Because the printed material travels through the printing press at speeds of up to 15 meters per second, the control algorithm has just 10 milliseconds to position the cut register. “To deliver the required speed and accuracy, we would have needed to completely rewrite our existing control software,” Debes says.

曼罗兰工程​​师需要一个开发环境，使他们能够测试新的控制算法，模拟和比较设计，并迅速构建实时控制器，以进行最终测试和部署。

曼罗兰将基于模型设计的数学工具用于设计，测试和实现在其最新印刷机上的剪切寄存器的生产就绪控制系统。

Working in Simulink^®, the project team built a plant model of the press that incorporated performance data gathered from an operating press. They then developed a Simulink model of the control system based on a proportional integral derivative (PID) controller and conducted open-loop testing of several control strategies to identify the optimal approach. The model incorporated counter and filter blocks from DSP System Toolbox™。状态流^®和Sim万博1manbetxulink编码器™were used to implement a finite state machine to control the operational states.

After linking the plant model with the controller model, the engineers ran closed-loop simulations in Simulink to validate the controller. When they were confident that the controller met the functional requirements in non-real-time simulations, manroland engineers used Simulink Coder to generate C code from the plant and controller models.

使用Simu万博1manbetxlink实时™，他们进行了实时模拟，在标准PC上执行工厂模型代码以及第二个PC上的控制器模型代码。通过用户数据报协议（UDP）和FieldBus通信的两个系统。

在控制器模型中，工程师使用Simulink实现了TCP/IP接口，该接口使他们能够从第三万博1manbetx计算机远程配置设置点值，例如机器速度。

他们使用Simulink植物万博1manbetx模型模拟异常压力行为，这通常很难在真实硬件上重建。辩论说：“我们能够在许多错误条件下测试控制器，我们原本无法测试。”

工程师通过微调控制器模型，然后使用Simulink Coder和Simulink实时重新生成和部署控制器，从而优化了性能。万博1manbetx

然后，他们将Simulink实时PC与工厂模型断开，并万博1manbetx使用相同的FieldBus和网络接口将其重新连接到Manroland客户站点的生产印刷机。由于模拟是如此准确，因此控制器立即按照生产环境设计，并且始终满足客户的错误率，准确性和响应时间的规格。